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Aprilia RSV Mille Workshop Service & Repair Manual # 1

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Basic Information Identification Make: Aprilia Model: RSV Mille Generation Model Generation: First Generation (SL1000) Codes Engine Code Family: Rotax V990 Introduction Market Position Market Segment: High-performance sportbike Target Audience: Aprilia RSV Mille owners, independent workshops, performance enthusiasts Competitive Analysis Competitors: Ducati 916/996, Honda VTR1000F, Yamaha R1, Suzuki TL1000R/S Key Features Vehicle Usp: V-twin engine performance, Italian design and handling Manual Value Proposition Cost Savings: Enables DIY maintenance and repair, reducing labor costs Technical Accuracy: Provides factory-level technical data and procedures Manual Details Coverage Areas Primary Coverage: Workshop Service and Repair Page Count Estimated Page Count: 400-600 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: Printed (Likely) Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, internal components, timing, valve clearance, lubrication system, cooling system, fuel system (carburetor/injection depending on variant) Engine Management: Ignition system, ECU, sensors, troubleshooting diagnostic codes Transmission Drivetrain: Clutch operation, gearbox disassembly and assembly, final drive, chain maintenance Chassis Suspension: Front fork (Öhlins/Marzocchi) overhaul, rear shock absorber adjustment and service, swingarm, steering head bearings Braking System: Brake caliper service, master cylinders, brake fluid replacement, disc and pad specifications Electrical System: Wiring diagrams, lighting system, battery, starter, charging system, instrument cluster, fuse/relay identification Fuel System: Fuel tank, fuel pump, fuel injectors (if applicable), carburetor tuning (if applicable) Bodywork Fairings: Fairing removal and installation, seat, fuel tank cover, minor bodywork repairs Procedures Included Scheduled Maintenance: Oil changes, filter replacements, spark plug replacement, chain lubrication and adjustment, valve clearance checks Troubleshooting: Diagnostic procedures for common problems, fault finding charts Repair Procedures: Step-by-step instructions for component disassembly, repair, and reassembly Technical Data Tables: Torque specifications, tolerances, fluid capacities, electrical specifications Technical Depth Depth Of Coverage: Comprehensive (from basic maintenance to complete engine and chassis rebuilds) Diagnostic Capability: Advanced diagnostics for engine management and electrical systems Manual Specifications File Format File Format Details: Printed manual, often on quality paper stock Print Quality Print Quality: Professional, typically with clear diagrams and text Binding Type Binding Type: Spiral bound or perfect bound for lay-flat usability Paper Type Paper Type: Durable, often glossy or semi-gloss for diagrams Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, 60-degree V-twin Displacement: 997.6 cc (998 cc) Bore X Stroke: 97 mm x 67.5 mm Valve Train: DOHC, 4 valves per cylinder Compression Ratio: 10.8:1 (approx.) Performance Horsepower: 128 hp @ 9,750 rpm (approx.) Torque: 98 Nm @ 7,500 rpm (approx.) Fuel System Fuel Delivery: Carburetor (Mikuni BSR 40) on early models, Fuel Injection (Weber Marelli) on later models Fuel Type: Unleaded gasoline, minimum 95 RON Lubrication System Oil Capacity W Filter: 3.2 Liters (approx.) Recommended Oil Viscosity: 10W-40, 15W-50 (API SG or higher, JASO MA) Cooling System Cooling Type: Liquid-cooled Coolant Type: Ethylene glycol based antifreeze/coolant Transmission Standard Transmission Type: 6-speed, constant mesh Optional Optional Transmission: N/A Features Clutch Type: Wet multi-plate Final Drive: O-ring sealed chain Transmission Oil Type: SAE 75W-90 API GL-4 or GL-5 gear oil Dimensions Exterior Length: 2020 mm (approx.) Width: 710 mm (approx.) Height: 1150 mm (approx.) Wheelbase: 1415 mm (approx.) Weights Dry Weight: 194 kg (approx.) Wet Weight: 212 kg (approx.) Wheels Tires Front Tire Size: 120/70-17 Rear Tire Size: 180/55-17 Front Brake: Dual 320 mm discs, 4-piston radial calipers (Brembo) Rear Brake: Single 220 mm disc, 2-piston caliper (Brembo) Safety Features Ratings Safety Ratings: N/A (Motorcycle specific safety features and regulations apply) Active Features Braking System Type: High-performance radial mount calipers, braided brake lines Suspension Adjustability: Fully adjustable front forks and rear shock absorber Passive Features Frame Type: Aluminum twin-spar frame Technology Features Infotainment Infotainment System: N/A (Basic instrument cluster) Instrumentation: Analog tachometer, digital speedometer, odometer, trip meters, coolant temperature gauge, warning lights Driver Assistance ABS Availability: Optional on some models, standard on later variants (e.g., RSV 1000 R) Connectivity Connectivity Features: N/A Maintenance Service Intervals Oil Change Interval: Every 6,000 km or 6 months, whichever comes first Chain Maintenance Interval: Lubricate every 1,000 km or after riding in wet conditions; adjust as needed Valve Clearance Check Interval: Every 12,000 km or 12 months Spark Plug Replacement Interval: Every 12,000 km Fluid Specifications Brake Fluid Type: DOT 4 Coolant Type: 50/50 mix of de-ionized water and quality antifreeze (e.g., Motul Inugel Optimal) Known Issues Common Wear Item: Clutch plates, rear shock absorber seals, rectifier/regulator Electrical Gremlins: Wiring harness degradation, stator issues on some models Fuel System Carb Models: Carburetor synchronization and cleaning can be critical for smooth running Part Numbers Oil Filter Part Number Example: HIFLOFILTRO HF153 or OEM Aprilia equivalent Air Filter Part Number Example: K&N HA-1000 or OEM Aprilia equivalent Vehicle History Brand Heritage Brand Focus: Italian manufacturer known for racing heritage and performance motorcycles Model Evolution Introduction Year: 1998 Key Changes Through Generations: Introduction of fuel injection (2000), revised chassis and suspension components, styling updates Production Production Period: 1998 - 2003 Manufacturing Location:...
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Aprilia RSV Mille Workshop Service & Repair Manual # 1
Basic Information
Identification
Make: Aprilia
Model: RSV Mille
Generation
Model Generation: First Generation (SL1000)
Codes
Engine Code Family: Rotax V990
Introduction
Market Position
Market Segment: High-performance sportbike
Target Audience: Aprilia RSV Mille owners, independent workshops, performance enthusiasts
Competitive Analysis
Competitors: Ducati 916/996, Honda VTR1000F, Yamaha R1, Suzuki TL1000R/S
Key Features
Vehicle Usp: V-twin engine performance, Italian design and handling
Manual Value Proposition
Cost Savings: Enables DIY maintenance and repair, reducing labor costs
Technical Accuracy: Provides factory-level technical data and procedures
Manual Details
Coverage Areas
Primary Coverage: Workshop Service and Repair
Page Count
Estimated Page Count: 400-600
Manual Type
Manual Type: Workshop Service Manual / Repair Manual
Language
Language: English
Format
Format: Printed (Likely)
Manual Coverage
Systems Covered
Engine Mechanical: Complete overhaul, internal components, timing, valve clearance, lubrication system, cooling system, fuel system (carburetor/injection depending on variant)
Engine Management: Ignition system, ECU, sensors, troubleshooting diagnostic codes
Transmission Drivetrain: Clutch operation, gearbox disassembly and assembly, final drive, chain maintenance
Chassis Suspension: Front fork (Öhlins/Marzocchi) overhaul, rear shock absorber adjustment and service, swingarm, steering head bearings
Braking System: Brake caliper service, master cylinders, brake fluid replacement, disc and pad specifications
Electrical System: Wiring diagrams, lighting system, battery, starter, charging system, instrument cluster, fuse/relay identification
Fuel System: Fuel tank, fuel pump, fuel injectors (if applicable), carburetor tuning (if applicable)
Bodywork Fairings: Fairing removal and installation, seat, fuel tank cover, minor bodywork repairs
Procedures Included
Scheduled Maintenance: Oil changes, filter replacements, spark plug replacement, chain lubrication and adjustment, valve clearance checks
Troubleshooting: Diagnostic procedures for common problems, fault finding charts
Repair Procedures: Step-by-step instructions for component disassembly, repair, and reassembly
Technical Data Tables: Torque specifications, tolerances, fluid capacities, electrical specifications
Technical Depth
Depth Of Coverage: Comprehensive (from basic maintenance to complete engine and chassis rebuilds)
Diagnostic Capability: Advanced diagnostics for engine management and electrical systems
Manual Specifications
File Format
File Format Details: Printed manual, often on quality paper stock
Print Quality
Print Quality: Professional, typically with clear diagrams and text
Binding Type
Binding Type: Spiral bound or perfect bound for lay-flat usability
Paper Type
Paper Type: Durable, often glossy or semi-gloss for diagrams
Engine Specifications
Primary Engine
Engine Type: Liquid-cooled, four-stroke, 60-degree V-twin
Displacement: 997.6 cc (998 cc)
Bore X Stroke: 97 mm x 67.5 mm
Valve Train: DOHC, 4 valves per cylinder
Compression Ratio: 10.8:1 (approx.)
Performance
Horsepower: 128 hp @ 9,750 rpm (approx.)
Torque: 98 Nm @ 7,500 rpm (approx.)
Fuel System
Fuel Delivery: Carburetor (Mikuni BSR 40) on early models, Fuel Injection (Weber Marelli) on later models
Fuel Type: Unleaded gasoline, minimum 95 RON
Lubrication System
Oil Capacity W Filter: 3.2 Liters (approx.)
Recommended Oil Viscosity: 10W-40, 15W-50 (API SG or higher, JASO MA)
Cooling System
Cooling Type: Liquid-cooled
Coolant Type: Ethylene glycol based antifreeze/coolant
Transmission
Standard
Transmission Type: 6-speed, constant mesh
Optional
Optional Transmission: N/A
Features
Clutch Type: Wet multi-plate
Final Drive: O-ring sealed chain
Transmission Oil Type: SAE 75W-90 API GL-4 or GL-5 gear oil
Dimensions
Exterior
Length: 2020 mm (approx.)
Width: 710 mm (approx.)
Height: 1150 mm (approx.)
Wheelbase: 1415 mm (approx.)
Weights
Dry Weight: 194 kg (approx.)
Wet Weight: 212 kg (approx.)
Wheels Tires
Front Tire Size: 120/70-17
Rear Tire Size: 180/55-17
Front Brake: Dual 320 mm discs, 4-piston radial calipers (Brembo)
Rear Brake: Single 220 mm disc, 2-piston caliper (Brembo)
Safety Features
Ratings
Safety Ratings: N/A (Motorcycle specific safety features and regulations apply)
Active Features
Braking System Type: High-performance radial mount calipers, braided brake lines
Suspension Adjustability: Fully adjustable front forks and rear shock absorber
Passive Features
Frame Type: Aluminum twin-spar frame
Technology Features
Infotainment
Infotainment System: N/A (Basic instrument cluster)
Instrumentation: Analog tachometer, digital speedometer, odometer, trip meters, coolant temperature gauge, warning lights
Driver Assistance
ABS Availability: Optional on some models, standard on later variants (e.g., RSV 1000 R)
Connectivity
Connectivity Features: N/A
Maintenance
Service Intervals
Oil Change Interval: Every 6,000 km or 6 months, whichever comes first
Chain Maintenance Interval: Lubricate every 1,000 km or after riding in wet conditions; adjust as needed
Valve Clearance Check Interval: Every 12,000 km or 12 months
Spark Plug Replacement Interval: Every 12,000 km
Fluid Specifications
Brake Fluid Type: DOT 4
Coolant Type: 50/50 mix of de-ionized water and quality antifreeze (e.g., Motul Inugel Optimal)
Known Issues
Common Wear Item: Clutch plates, rear shock absorber seals, rectifier/regulator
Electrical Gremlins: Wiring harness degradation, stator issues on some models
Fuel System Carb Models: Carburetor synchronization and cleaning can be critical for smooth running
Part Numbers
Oil Filter Part Number Example: HIFLOFILTRO HF153 or OEM Aprilia equivalent
Air Filter Part Number Example: K&N HA-1000 or OEM Aprilia equivalent
Vehicle History
Brand Heritage
Brand Focus: Italian manufacturer known for racing heritage and performance motorcycles
Model Evolution
Introduction Year: 1998
Key Changes Through Generations: Introduction of fuel injection (2000), revised chassis and suspension components, styling updates
Production
Production Period: 1998 - 2003
Manufacturing Location: Italy
Awards & Recognition
Recognitions
Performance Reviews: Consistently praised for its V-twin torque, chassis dynamics, and track capability in contemporary motorcycle reviews.
Ratings
Motorcycle Review Sector: Superbike, Sport-Touring capability
Certifications
Manual Certification: Unofficial (produced by aftermarket specialist, but based on factory data)
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